Process of producing compound metal bodies.



J. P. MONNOT. PRoGEss 0F PEODUGING GoMPoUND METAL BODIES.

APPLICATION FILED NOV.12, 1906.

Patented Jan. 26, 1909.

INVENTOR fri.; MM

(2mm, ATTORNEYS WITNESSES: MMM/amy UNITED STATES PATENT Ormea.

JOHN F. MONNOT, OF New YORK, N. Y., AssIcNon To DUPLEX METALS' COMPANY, or NEW YORK, N. Y., A CORPORATION or New YORK.

Pnocn'ss or Pnonucme ooivrroUND METAL BoDms.

Application filed November 12, 1906. vSerial No. 343,033,

To all whom it may concern:

Be it known that I, JOHN F. MoNNoT, a citizen of the United States, residing at New York, in the county of New York and State of New York, have invented a certain new and useful Process of Producing Compound Metal Bodies; and I do hereby declare the following to Vbe a full, clear, and exact description of the same, such as will enable others skilled in the art to which it appertains to make and use the same. My invention relates to a process of producing compound metal bodies com osed of layers or strata of unlike metals weded Itogether (such as iron or steel, autogenously and completely Welded to cop er, silver, gold, brass, bronzes, aluminum, etcg. My invention consists in the novel method of weld-uniting unlike metals such -as described.

' According to my said invention I place .within a suitable mold, a sheet or layer of one of the said metals, preferably the one of lower melting point, and then pour into the mold the other said metal, causing the molten metal to solidify against the surface of the first metal, and to unite therewith. After the-ingot has solidified it is subjected to Working to condense the cast metal and to insure perfect union between the metals.

In uniting unlike metals b casting one against the other, as describe it is exceedingl. important, in order that there may be pe ect union at allppoints between the cast metal and the metal against which the same is cast, that the surface of the latter metal subjected to the action of the molten metal,

. shall be entirely clean and free from oxid,

scale, etc., and that it shall be maintained in such condition during the operation. This erfeot cleanliness of surface has been very difficult, if not impossible, to secure -by the methods heretofore used.. The solid metal,

particularly if thin, is heated uprapidly by the molten metal, as the latter'rises in the mold, and thehot 'metal still exposed to air` tends to oxidize very rapidly. Furthermore, steel as ordinarily cast, carries with it considerable quantities of oxygen and other gases some of which tend, or may tend, to attack the Vsurface of the copper or other metal against which the steel 1s cast, or to make blow-holes, pores, or flaws at the point 0f unionof the two metals, which flaws or Specication of Letters Patent.

, Patented .im 26, 1909.

the like persist during the subsequent working of the ingot.

According to my invention I secure and material serving to clean the surface of oxids as it fuses vunder the heat of the casting operation and the neutral atmosphere serving to mamtam the clean surface when onceformed.

vFor the non-oxidizing or protective atmosphere I may employ producer gas made from coke, charcoal or anthracite, and which therefore contains no material proportion of decomposable hydrocarbons. The rotect ive paint may contain a powder o one or more of the readily-fusible oxygen-absorbing metals havlng a reducing power sufficient to reduce the oxids of the metals to be united say, any of the metals or substances which' 'are known to have a purifying or cleaning action on the steel or other molten metal) in the .runner during the pouring. Thereby oxygen and other deleterious gases in the molten metal 'are removed; v. As thel molten metal is cast and rises in the mold, the protect'ive coating mentioned melts away and rises as a slag, together with any aluminum or other oxid formed, thus exposing a clean surface to the action ofthe molten metal. `The coating, in so dissipating, tends to re- Vent collection of gases 1n bubbles or the ike at the point of union Of the two metals. By pouringthe mold from the bottom I avoid the entraining` of air by the down-flowing stream 'of metal` at a point so near the. surface of the. metal against which the moltenmetal is cast that there is not sufficient-opdiagrammatically and in vertical section,l

.apparatus such as may be employed for Vducing a solid inggot coated on al for example as a the ingot mold is ing out my said invention.

I ave shown apparatus arranged for prosides with coating metal. ut it will be obvious that my invention is not limited to producing compound ingots coated on all sides, or to the production of solid coated ingots or in ots coated on the outside.

the said drawings, 1 designates an ordinary ingot'mold, 2 a pouring table, 3 a runner for such table, and 4 a passage leading from the runner 3 to the ingot mold and entering same at the bottom. customarily line the runner and the said passage with refractory material 5, as shown. h ithn the ingot mold I place a hollow shell 7 composed of the metal of which the coatin is to be made (copper for example), said s ell being protected (preferably) on the side against which the molten metal is to be cast, with a layer 8 of fusible protective material, such aint composed of aluminum powder and silicate of soda. Likewise provided with a cap 9 having a pipe 10 for introducing a protective atmosphere, such as producer gas; the gas so introduced being introduced at low pressure, and filling the mold, passing thence through passage 4 into the runner 3 and thence outward; or it may be burned in the runner, o'r at the mouth thereof. Because of the low pressure atwhich the gas is introduced, it will not prevent the passage of molten 'metal from the runner into the mold, but

will be forced' back by the molten metal, kee ingall portions of the shell 7 not covere with the molten metal in anon-oxidizin atmosphere and 'preventing useless oxidation of the powdered metal in the protective paint.

Before applying the protective layer to the coating metal or metal against which the molten metal is to be cast, I first clean thoroughly the surface 'against which the l molten metal is to be cast, and then apply said coating, which then tends to prevent oxidation of the surface to be protected, even before the protective atmosphere is introduced into the mold. 'Ihis protective coating in melting exerts to some extent a specificcleaning action of its own.

a mold, molten metal is In Cpourin poure into t erunner 3 and caused to ass through passage 4 into the ingot mold 1, forcing back into pipe 10 the protective atmosphere, rising 1n the mold and as it does so melting QH the rotective coating 8 and contacting with a c ean metallic surface of the shell 7, the protective coatin as it 1s melted off rising as a slag. I intro uce into the runner, at suitable times, pieces of aluminum, magnesium, cadmium, titanium, or other oxygen-absorbing or gas-absorbing or purifying material, so as to free the molten metal from gases dissolved therein or carried thereby and so insure a good quality of cast metal and remove any oxygen present 'lhe ingot having been cast as described, and the molten metal having solidified, the ingot is removed from the mold, and is worked, either directly or after submission to a soaking heat, whereby the cast metal is condensed and absolute union of the two metals is assured. 'l his working may be effected by assing the ingot between rolls, or by sub- ]ecting it to the action of a press or a hammer, or by forcing the ingot, while the cast metal is still in a pasty condition, through a contracted die-orifice, as set forth in the Letters Patent to Edouard Martin and myself No. 853,932 dated May 14th, 1907 or the metal may be subjected to pressure during and after solidification and While still pasty, to which end I ma move the mold with the ingot within it un er a press and apply pressure to the contents of the mold by means of such press. Pressure applied on any of these ways prevent-s the molten metal from shrinking away from the other metal during or after solidification.

Preferably the metal cast asl above described is metal havin a melting point near or hi her than the me ting point of the solid meta to be united to the metal so cast. In such case the molten metal causes fusion or semi-fusion of the surfaces of the coating metal with which it contacts. For example, in the production of steel-copper or steelsilver ingots, I prefer that the copper or silver shall be used in solid condition and the steel cast molten against them. But when preferred or necessary, the metal of lower melting point, may be the metal which is cast; in

such case the molten metal being heated other of these two protections maj)r be omitted and the other used alone, but by con` joint use of the reducing protective paint and the neutral atmosphere important advantages are gained. The neutral atmosrot phere at casting temperature while preventing oxidation does -not ordinarily have much e'eet in reducing oxids already formed, so that in operating Without the reducing aint it is necessary to have the surface o the metal shell/Very clean from the be inning While in using the protective paint a one, if

it be, as it customarily is, a relatively thinlayer or film, there is much danger of the air in the mold .oxidizing its contained powdered metal as the shell heats up under the heat of the advancing molten metal.

What I claim is 1. The process of uniting metals, which comprisesapplying to a substantially clean surface of a body of one metal a fusible protective and deoxidizing coating containing a reducing body capable of reducing the oxids of the metals to be treated, casting against such surface a body of molten metal, and by the heat of the molten metal fusing such protective coating and causing same toleave the coated surface thereby exposing a clean metallic surface to the action of the molten metal.

2. The process of uniting metals, which comprises applying to a substantially clean surface of a body of one metal a fusible protective coating comprising a readily fusible metal capable of reducing oxids of the metal of such body, casting against such surfaces a body of molten metal, and by the heat of the molten metal fusing such protective coating and causing same to leave the coated surface, thereby exposing a clean metallic surface to the action of the molten metal.

3. The process of uniting metals, which comprises a plying to a substantially clean surface of a ody`pf one metal a fusible protective coating comprising aluminum, cast# j ing against such surface a body of molten metal, and by the heatof the molten metal fusing such. protective coating and causing same to leave the coated surface, 'thereby exposing a clean metallic surface to the ac- .tion of the molten metal.

4. The process'of uniting metals, which comprises a plying to a substantially clean surface of a ody of one metal a fusible pro-` the action of the molten metal.

- silicate of an alkali, casting againstsuch sur' 5. The process of uniting metals, which comprises applying to a substantially clean surface of a body of one metal a fusible protective coating comprising aluminum and tive coating and causing same to leave the a cleanI coated surface, thereby expos' -metallic surface to the action of t e molten metal. p

6l The process of uniting metals which comprises applying to a substantially clean surface of a body of one metal a fusible rotective coating comprising a gas-absor in me tal capable of reducing oxids of the meta coated, casting against such surface a bodyof molten metal and lby the heat of the molten metal fusing such rotective coating and causing the same to eave the coated surface, thereby exposing a clean surf-ace to the action of the molten metal.

7. Theprocess of uniting metals, which comprises applying to a substantially clean surface of a bodyof one metal a fusible protective coating comprising a metal of the thereby displacing such atmosphere and causing the molten metal to contact with such surface. s

9. The process of uniting metals, which consists in enveloping a surface of a body of one metal in place in a mold, with aprotective non-oxidizing atmos here, said surface having applied to it a fusi le protective coating, and introducing molten metal into said mold and thereby dis lacing such atmosphere and melting an displacing the protective coating and causing the molten metal to contact With such surface.

10. The rocess of uniting metals, which comprises p acing a body of one metal within a suitable mold, protecting the surface of such body against chemical or other attack,

by enveloping such surface with a displaceable substance, lcontaining a reducing substance capable of reducing oxids of the metal of such body, purifyinga body of molten metal by introducing therein a urifying substance and then introducing such molten metal into .the mold and causing samesto displace such protective substance and contact with ,the surface protected. i

In testimony yvhereof I affix my signature, in the presenceof two Witnesses.

JOHN F. MoNNo'r.

Witnesses H, M. MARBLE,

.BYRON E. ELDRED. 

